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Author Topic: 83 Suzuki GS650 Shafty - Better Late Than Never  (Read 12665 times)

Offline Jonny_C

  • Posts: 150
83 Suzuki GS650 Shafty - Better Late Than Never
« on: Jun 04, 2015, 16:35:23 »
I purchased this bike in 2012 and started tearing it down and doing some modifications.  Soon after I relocated from Madison, WI to Green Bay, WI and bought a house with a decent garage.  I had plans to work on the bike right away after I moved in, but two years later I'm finally getting around to it.

Here's what it looked like when I started tearing it down when I first got it...









Had the wheels powdercoated along with getting some new Kenda tires...



I had polished the side covers, front forks, replaced the seals in the forks and installed Sonic springs. I tack welded closed the port for the air valve as well since I ditched that.  This is how it sat for two years.



In my new place.  See the bike back there?  No?  It's there somewhere.



Finally cleaned up the garage enough and started unpacking parts that I didn't even remember purchasing...



Started building a electronics tray and picked up a Millermatic 140 in the process...









Unpacked these babies after sitting in a box for two years.  Completely rebuilt (cost about $250 in parts), polished, jetted.



Tossed the GS850 tank on that I had purchased from a member on here (still need to build mounts), and put on the Hagon shocks.







Got some basic wiring done and fired it up last night!  One plug wire was cut and spliced back together. Tried to solder it just to get by, but that coil was getting crazy hot.  Ordered up some Dyna coils and wires.  Also have a SH-775 R/R on the way (had bought a FH-009 but got talked into the nice series regulator on the GS Resources forum), along with wiring loom, Weather Pack connectors, and left side controls off of a GSX-R.

A lot of work to do.  Weld up a rear loop, figure out the rear set mounting (it might be too far back as shown in the pic, but that's the only good mounting location), mount tank, figure out what petcock to use, turn signals, tach/speedo, new cables, ugh.  Still plan on doing an RFID ignition using a relay, have all of the parts for that as well.

I was previously working on a Arduino tachometer, but I doubt I'll end up doing that.  Might just use the standard mechanical tach and speedo cables with some aftermarket gauges.

Offline Jonny_C

  • Posts: 150
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #1 on: Jun 12, 2015, 16:13:33 »
Made a bracket for the front mount of the tank...



Cut out the hoop to get it ready for welding...


Offline specialk

  • Posts: 21
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #2 on: Jun 12, 2015, 18:53:32 »
Loving the progress so far! This is going to be one heck of a GS when you are done with it! I also have an 83 GS650, I've refrained from modify the frame in any way but I may get around to it someday.  I'm looking forward to seeing the bike progress.

Offline Jonny_C

  • Posts: 150
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #3 on: Jun 12, 2015, 19:04:52 »
Loving the progress so far! This is going to be one heck of a GS when you are done with it! I also have an 83 GS650, I've refrained from modify the frame in any way but I may get around to it someday.  I'm looking forward to seeing the bike progress.
Nice!  I didn't think anyone else owned the same bike, it seems to be the redheaded stepchild of the GS's.

Offline specialk

  • Posts: 21
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #4 on: Jun 12, 2015, 19:23:43 »
Nice!  I didn't think anyone else owned the same bike, it seems to be the redheaded stepchild of the GS's.
No kidding! Still holds it's own against the big blocks though. Are you running a 4-1 pipe on yours?

Offline Jonny_C

  • Posts: 150
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #5 on: Jun 12, 2015, 19:44:03 »
No kidding! Still holds it's own against the big blocks though. Are you running a 4-1 pipe on yours?

Yeah, Mac exhaust. Thing was too expensive for the quality, but its the only option. When I fired up the bike I only seemed to be on 3 cylinders, so once I get new wires in my coils I'll need to check out the carbs if its still happening.

I get discouraged by how much work I need to do just to get the thing on the road.

Offline specialk

  • Posts: 21
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #6 on: Jun 12, 2015, 19:49:03 »
I see, I'm sure once you hear it screaming on all 4 you'll forgot about the price.  The original mufflers and mid pipe were rotted out on mine so I cut it off and welded on some shorty mufflers, the end result sounds great and looks pretty good too.

Try to keep your motivation high, you're off to a great start and its going to look great when you are done. 

Offline Jonny_C

  • Posts: 150
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #7 on: Jun 18, 2015, 15:07:28 »
Thanks specialk, I appreciate the motivation :)

I have the rear hoop welded up.  Wanted a slight kick, but didn't have the means to bend the kick into the already bent up hoop I purchased.  Instead I just cut it at an angle and bought 7/8" metal spacers that I turned down on my lathe to fit the larger tubing of the hoop.  Welded mounting bracket (which I will trim down) for an integrated brake/turn rear light.  Pretty bad welding, but it should be solid.

Now I need to weld up some rearset brackets, an under-tank mount on the rear of the tank (seat will slide under the tank a bit, with the stock mounting tabs of the tank trimmed off), and start on the seat pan.







Offline specialk

  • Posts: 21
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #8 on: Jun 18, 2015, 15:10:30 »
Looks good! That should work nicely for you. What are you going to use for the seat pan? Sheet metal or the skate board deck method?

Offline Jonny_C

  • Posts: 150
Re: 83 Suzuki GS650 Shafty - Better Late Than Never
« Reply #9 on: Jun 18, 2015, 15:23:17 »
Looks good! That should work nicely for you. What are you going to use for the seat pan? Sheet metal or the skate board deck method?

Sheet metal.  My mom has done some upholstery work, so I'm going to have her help me.  Might use screws on the bottom instead of rivets?  I don't know.  Going to try to emulate this seat...

http://www.thegsresources.com/_forum/showthread.php?173563-Pictures-of-my-custom-seat&p=1405227#post1405227